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From a website I used to size my system for a GT40...
You may use the following as a fuel pump "rule of thumb". Additionally, it is a good idea to give your system a bit of safety cushion.
I always run a pump just a bit larger than I need just for insurance.
For Dead-Head type regulators:
Multiply maximum horsepower by .23 to calculate minimum pump size in "free flow" GPH.
Example: 400 HP x .23 = 91 GPH "free flow"
For Return-Style regulators:
Multiply maximum horsepower by .17 to calculate minimum pump size in "free flow" GPH.
Example: 400 HP x .17 = 68 GPH "free flow"
These minimum pump sizes assume that the fuel system is equipped with fuel lines of adequate size. If the fuel lines are too small (or if there are a lot of restrictive fittings in the system) a larger pump may be required to satisfy the fuel demand of the engine. The minimum fuel line size (from the pump to the regulator) is dependent on the horsepower output of the engine (and/or Nitrous system) regardless of the size of the pump.
Use these figures as a fuel line sizing standard:
* Up to 250 HP = 5/16" or -04 AN
* Up to 375 HP = 3/8" or -06 AN
* Up to 700 HP = 1/2" or -08 AN
* Up to 1000 HP = 5/8" or -10 AN
* Up to 1500 HP = 3/4" or -12 AN
If you use a return-style regulator, you will also need a return line from the regulator back to the tank. The size of the return line is dependent on the size of the pump you are using, regardless of the engine's horsepower output. The return line must have limited or NO pressure in it. In most cases, the minimum return line size will match that of the supply line, but a larger return line is sometimes preferred.
Use these ratings to decide your return line sizing based upon fuel pump output:
* Up to 45 GPH = 5/16" or -04 AN
* Up to 90 GPH = 3/8" or -06 AN
* Up to 250 GPH = 1/2" or -08 AN
* Up to 450 GPH = 5/8" or -10 AN
* Up to 900 GPH = 3/4"or -12 AN
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